Outside Door Handles May Break on Chevrolet Astro

The outside door handles are prone to breaking—all doors are affected by this condition.

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Average mileage: 144,065 (13,115–258,000)
16 model years affected: 1990, 1991, 1992, 1993, more1994, 1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003, 2004, 2005
82 people reported this problem
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Viewing 1 - 20 of 39 problem details
The handle broke on the outside of the van, and won't open from the inside.
2003 Chevrolet Astro 175,000 mi,
handle broke can open back door
2003 Chevrolet Astro 170,000 mi,
Back door handle stopped working.
2005 Chevrolet Astro 100,000 mi,
Both door handles broken....have ordered new ones. Seems to me another Government Motors (GM)design flaw..!! Can't wait for Nomobama care to start up...(once we can ACTUALLY sign up for it)...on that gubmnt' web site..!!
Door handle busted. Am replacing it now
same problem also my electrical windows don't work
1995 Chevrolet Astro 105,000 mi,
I had the same problem with the driver's door. You can buy the replacement handles at the auto parts store. I followed the instructions in my Haynes manual with some success. It took myself longer to than what the instructions stated, and I had to disassemble the lock assembly to put everything back together. This part wasn't apart of the instructions.
1998 Chevrolet Astro 170,000 mi,
drivers side and rear barn door handles broke.
1994 Chevrolet Astro 153,000 mi,
All door handles have broken but the sliding side door
First driver side at about 140,000 and then pass side at 150,000 outer door handles broke and had to be replaced.
1997 Chevrolet Astro 205,000 mi,
rear door handle snapped off - also, doors are stuck closed after spring assembly seems to have fallen apart inside the door.
1995 Chevrolet Astro 208,000 mi,
Drivers side door exterior handle, lock rod kept coming off. I went to my local Chevy dealer. One of the guys gave me 4 of both size nylon washers
2000 Chevrolet Astro 130,000 mi,
All my door handles are broken.
2000 Chevrolet Astro 120,000 mi,
Bottom under handle broke first.Then handle broke all the way drivers side.in the process of having repaired
1996 Chevrolet Astro 150,000 mi,
Every Astro van we've used in our business has had major issues with door handles breaking. '91,'93,'96. Chevrolet needs to quit using cheap pig iron to make these; we've cleaned out area junk yards of their chevy astro door handles. Not so hard to fix, but pain in butt to find used. Have tried new replacements and they are just as inferior.
1998 Chevrolet Astro 125,000 mi,
Door handles broke.....all of them.
2004 Chevrolet Astro 146,000 mi,
This is a common problem in Chevys. My family has owned several Suburbans & Chevy trucks with the same problem. The issue is not the door handle itself, but the spring that releases the door wears out, causing passengers to pull again and again on the handle because the door is hard to open. You can replace the handle, but without replacing the spring, it will happen again.
1990 Chevrolet Astro 119,000 mi,
Door handles front doors both broke off
Front power locks quit working
2003 Chevrolet Astro 96,000 mi,
door handle of driver side is broken